Method of forming brake levers



Dec. 29, 1 25. 1,567,353

L. L. WHITNEY METHOD OF FORMING BRAKE LEVERS Filed July 14, 1924 Y 2Sheets-Sheet 2 I 5 51 r Mme =3 Patented Dec. .29, 19 25.

''UNITED STATES PATENT OFFICE.

LOREN L. WHITNEY, OE HAMMOND, INDIANA, ASSIGNOR '1'0 AMERICAN STEELFOUNDRIES, OF CHICAGO, ILLINOIS, A CORPORATION OF NEW JERSEY.

METHOD OF FORMING BRAKE LEVERS.

Application filed July-14,1924. Serial No. 725,788.

To an whom it may concern:

Be it known that I, LOREN L. wmm,

Figure 21 is a-front view of the hammer dies;

1 a citizen of the United States, residing at\ Figure 22 is a view ofthe hammer dies as Hammond, in the county of Lake and State of Indiana,have invented certam new and useful Improvements in Methods of FormingBrake Levers, of Wl'llCh the following is a specification.

' This invention relates to a new and improved method of forming brakelevers and more particularly to a method of fornnng dead brake leversprovided wlthtrunmons from which they are supported.

It is an object of the present invention to provide a method of thischaracter adapted to form levers of this type from slmple blanks bymeans 'of a serles of hammering and for in 0 erations;

-It is a ffi'th r object to provide a method of this character in whichprovision 1 s made for the removal of excess metal during the forgingoperation.

It is an additional ob ect to provide a method comprising a series ofsimple steps adapted for rapid commercial production.

Other and further objects W111 appear'as the description proceeds.

I have illustrated in the accompanying drawings the blanks used as theyappear in different steps of the operation, and have also shown the diessuitable for performing these steps.

In the drawin Figure 1 is a side view of the blank;

Figure 2. is an end vlew of Flgure 1;

Figure 3 is a top view of the blank after the first hammeringOPBIHJZIOIU Figure 4 is a face View of Figure 3;

Figure 5 is an end v ew of Figure 3;

Figures 6, 7, and 8 are views similar to Figures 3, 4, and 5, but shOWthe blank after the second hammering operation;

Figures 9,10, and 11 are views similar to Figures 3, 4, and 5, but showthe blank after the third hammerin operation;

Figures 12, 13, an 14 are views similar to Figures 3, 4, and 5, but showthe blank after the first forging operation;

Figures 15, 16 and 17 are similar to Fig ures 12, 13 and 14, but showthe blank after the removal of excess metal.

Figures 18, 19 and 20 are similar to Figures 12, 13, and 14, but showthe blank after the second and final forging operation;

seen from the left;

Figures 23 and 24 are perspective views of the forging dies;

Figure 25 is a perspective view of the first pass plunger; and

Figure 26 is a perspective viewof the second pass plunger. The blank 31,as shown in Figures 1 and 2, s rectangular in form. In the firsthammermg operation one end of the blank 32 is used as a holder andtheother end 33 is flattened between the hammer die portions 34 and 35.It is also shaped to the form shown in Figure 4 by means of the hammerdie portions 36 and 37. This forms the right or connecting end of thelever to approximately its finished form. Next, the intermediate portion38 of the lever is brought to the form shown in Figure 7 by means of thehammer die portions 39 and 40. The flattened portion of the lever isthen brought to the final form shown. in Figure 10 by means of thehammer die portions 41 and 42, the connecting end being rounded as shownat 431 During these hammering operations the blank has been reversedoccasionally and the portion 32 of Figure 4 has been somewhat flattenedas shown at 44, this flattoning being in a plane at right angles to theplane of the body of the lever.

Now, using the body of the lever as a holder, the portion 44 of theblank is introduced into the lower recesses 45 and 46 of the dies 47 and48, shown in Figures 23 and 24. It will be noted that the recess 46 isprovided with a laterally extending cavity 47 adapted to receive excessmetal. The dies 47 and 48 are brought together and the plunger 49 hasits portion 50 introduced into the recesses 45 and 46 and against theend of the portion 44. This portion is now brought to the form shown at51 in Figures 12 to 14. Any excess metal is forced into cavity 47 andforms the irregular boss 52. This provision of means for taking care ofthe excess metal prevents stalling or breaking of the forging apparatus.The excess metal52 is next removed, preferably by a hot sawingoperation, and the blank assumes the form shown in Figures 15 to 17.

The blank is now placed in the upper re- 10 to pivot or connecting pins.

cesses 53 and 54 of the dies 47 and 48, and the plunger 55 shown inFigure 26 has its portlon 56 brought against the portion 51 of theblank. This final forging operation 5 brings the blank to the form shownin Figures 18 to 20, having the laterally extending trunnions 57 and 58.In preparing the lever for use, the portions 38 and 43 will be suitablydrilled to provide for their connection While the method has beendescribed as applied to the forming of one specific form of lever, it isobviously capable of forming other levers by suitable change in diedesign, and I contemplate such modifications as come within the scope ofthe appended claims.

I claim:

1. The method of forming a brake level or the like, which compriseshammering a blank to form the body and connecting portions of the lever,forging one end to form trunnions thereon, and sawing from the trunnlonsexcess metal from the forging Y 25 2. The method of forming a brakelever operation.

or the like, which comprises hammering a blank to form the body andconnecting portions of the lever, forging one end to partially formtrunnions thereon, removing excess metal of this forging operation, andagain forging the trunnion end to complete the formation of thetrunnions.

Signed at Hammond, Indiana, this 9th day of July, 1924.

LOREN L. WHITNEY.

